On-line detection device for high fructose corn syrup

Abstract

The invention discloses a high fructose corn syrup on-line detection device, and relates to the technical field of high fructose corn syrup detection, and the high fructose corn syrup on-line detection device comprises a multi-parameter detection unit which comprises a first on-line near-infrared analyzer, a second on-line near-infrared analyzer, a third on-line near-infrared analyzer, a first refractometer, a second refractometer and a pH sensor; the data acquisition and transmission unit comprises an intelligent gateway and an industrial-grade isolation gatekeeper; the SPC dynamic control unit comprises an industrial server, a communication module and a display terminal; and the abnormity early warning module is integrated in the industrial server and is connected with the audible and visual alarm and the PLC controller. Through multi-sensor cooperative detection, real-time data transmission and SPC dynamic analysis, real-time adjustment of production parameters is achieved, stable product quality is ensured, and meanwhile labor and detection cost is reduced.

Description

Technical Field

[0001] The present application relates to the technical field of high fructose corn syrup detection, for example, to an online detection device for high fructose corn syrup. Background Art

[0002] Currently, during the production of high fructose corn syrup (e.g., F55), the fructose content, solids concentration, and pH value of key processes such as isomerization and chromatographic separation must be strictly monitored. Traditional detection methods rely on manual sampling and offline laboratory analysis (e.g., liquid chromatography), but have the following drawbacks: Detection lag: A single test takes about 30 minutes, and data cannot be fed back in real time, resulting in delayed production adjustments, which can easily lead to indicator fluctuations and quality risks.

[0003] High labor costs: Frequent sampling and testing are required, which consumes a lot of manpower and reagents, and the amount of data is limited, making it difficult to meet the needs of high-precision process control.

[0004] Lack of integrated monitoring: Existing online detection equipment is mostly limited to single parameter measurement and is not deeply integrated with the production control system, making it impossible to achieve multi-parameter linkage analysis and instant correction.

[0005] Therefore, existing technologies are difficult to meet the needs of real-time detection of multiple parameters, instant data feedback and intelligent process control in fructose-glucose syrup production. There is an urgent need for an integrated online detection device to improve quality stability and reduce detection costs. Summary of the Invention

[0006] In order to provide a basic understanding of some aspects of the disclosed embodiments, a brief summary is given below. The summary is not an extensive review, nor is it intended to identify key / critical elements or delineate the scope of protection of these embodiments, but rather serves as a prelude to the detailed description that follows.

[0007] In order to solve the above technical problems, the present application provides an online detection device for high fructose corn syrup; the online detection device for high fructose corn syrup realizes instant adjustment of production parameters through multi-sensor collaborative detection, real-time data transmission and SPC dynamic analysis, thereby ensuring stable product quality and reducing labor and detection costs.

[0008] The present application provides an online detection device for high fructose corn syrup, comprising: Multi-parameter detection unit: The first online near-infrared analyzer is deployed at the outlet of the isomerization column to detect the fructose content after isomerization in real time; the second online near-infrared analyzer is installed in the chromatographic feed pipeline to detect the fructose content of the chromatographic feed in real time; the third online near-infrared analyzer is set at the outlet of the evaporation process to monitor the fructose content of the final product of high fructose corn syrup; The first refractometer is installed at the outlet pipe of the isomerization column to detect the solid concentration in real time; the second refractometer is installed at the outlet pipe of the evaporation process to continuously monitor the solid concentration of the final product; The pH sensor is fixed to the inner wall of the mixing tank through a clamp-type fixing bracket to detect the pH value in real time; Data acquisition and transmission unit: It includes an intelligent gateway and an industrial-grade isolation network gate. The intelligent gateway is connected to the multi-parameter detection unit via the Modbus / TCP protocol, and the isolation network gate transmits data to the SPC dynamic control unit; SPC dynamic control unit: The system includes an industrial server, a communication module, and a display terminal. The industrial server is equipped with a data processor and memory for running the SPC analysis algorithm. The communication module connects to the production line PLC system via the OPC UA protocol. The display terminal displays a fructose content trend chart, a solids concentration curve, and a pH fluctuation thermodynamic chart in real time. Abnormal warning module: Integrated into industrial servers and connected to sound and light alarms and PLC controllers, it is used to trigger alarms and parameter adjustment instructions based on preset thresholds.

[0009] In a further improvement of the present invention, the spectral scanning frequency of the first online near-infrared analyzer, the second online near-infrared analyzer and the third online near-infrared analyzer are all ≥1 time / minute, the detection error range is ≤±0.5%, and they are respectively fixed to the middle section of the pipeline at the outlet of the isomerization column, the chromatographic feed pipeline and the evaporation process outlet through flange interfaces.

[0010] In a further improvement of the present invention, the resolution of the first refractometer and the second refractometer are both ≤0.1%, and are integrated with temperature compensation modules, which are respectively installed on the 316L stainless steel brackets of the isomerization column outlet pipe and the evaporation process outlet pipe.

[0011] In a further improvement of the present invention, the pH sensor uses a corrosion-resistant glass electrode with a detection accuracy of ±0.05, and the clamp-type fixing frame is made of polytetrafluoroethylene and is fixed to the inner wall of the mixing tank by bolts.

[0012] In a further improvement of the present invention, the abnormal warning module sets the fructose content threshold range to ±1.5%, the solid concentration threshold range to ±0.3%, and the pH value threshold range to ±0.1. When the limit is exceeded, an alarm is issued through an audible and visual alarm, and the operating parameters of the isomerized column temperature valve, the chromatographic feed pump and the evaporator pressure valve are adjusted through the PLC controller.

[0013] In a further improvement of the present invention, the data tracing system of the SPC dynamic control unit includes a data storage server and a historical database, supports the generation of SPC reports containing X-bar control charts, trend analysis curves and Cpk value calculation results, and exports them through a display terminal.

[0014] In a further improvement of the present invention, the intelligent gateway has a built-in embedded processor and a flash memory, which performs filtering, normalization and outlier removal operations on the detection data and then transmits it to the SPC dynamic control unit via industrial Ethernet.

[0015] In a further improvement of the present invention, the device also includes a 316L stainless steel mounting bracket, and the first online near-infrared analyzer, the second online near-infrared analyzer and the first refractometer are fixed to the outer wall of the pipeline through the mounting bracket, and the surface of the bracket is covered with a food-grade epoxy coating.

[0016] In a further improvement of the present invention, the communication module is connected to the production line PLC system via the RS-485 interface and the OPC UA protocol to adjust the opening of the isomerized column temperature valve, the speed of the chromatographic feed pump, and the pressure value of the evaporator pressure valve in real time.

[0017] In a further improvement of the present invention, the device is compatible with F55 fructose syrup, starch sugar and maltose syrup production lines, realizes rapid switching by configuring modular sensor interfaces and parameter preset templates, and supports cloud data synchronization and remote monitoring functions.

[0018] Compared with the prior art, this application has the following beneficial effects: This application realizes real-time monitoring and closed-loop control of fructose content, solid concentration and pH value in the production process of high fructose corn syrup through multi-node deployment of online near-infrared analyzers, refractometers and pH sensors, combined with SPC dynamic control units. The device has the advantages of easy installation, low cost and high precision, which can significantly improve product quality stability and reduce testing costs. It is suitable for the processing of liquid foods such as high fructose corn syrup and starch sugar.

[0019] The above general description and the following description are exemplary and explanatory only and are not intended to limit the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the background technology or the technical solution of the present application, the following is a brief introduction to the drawings used in conjunction with the prior art or specific implementation methods; obviously, the structures, proportions, sizes, etc. depicted in the drawings of the specification are only used to match the contents disclosed in the specification for people familiar with this technology to understand and read, and are not used to limit the conditions under which the present application can be implemented, so they have no technical significance. Any structural modification, change in proportional relationship or adjustment of size should still fall within the scope of the technical content disclosed in the present application without affecting the efficacy and purpose that can be achieved by the present application.

[0021] Figure 1 This is a structural block diagram of a specific implementation method of this application. DETAILED DESCRIPTION

[0022] In order to enable a more detailed understanding of the features and technical contents of the embodiments of the present application, the implementation of the embodiments of the present application is described in detail below in conjunction with the accompanying drawings. The attached drawings are for reference only and are not used to limit the embodiments of the present application. In the following technical description, for the sake of convenience of explanation, multiple details are provided to provide a full understanding of the disclosed embodiments; however, one or more embodiments can still be implemented without these details; in other cases, to simplify the drawings, well-known structures and devices may be simplified for display.

[0023] The terms "first", "second", etc. in the embodiments of the present application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence; it should be understood that the data used in this way can be interchanged where appropriate for the embodiments of the present application described herein; in addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions.

[0024] In the embodiments of the present application, the terms "upper", "lower", "inside", "middle", "outside", "front", "back", etc. indicate directions or positional relationships based on the directions or positional relationships shown in the accompanying drawings; these terms are mainly used to better describe the embodiments of the present application and its embodiments, and are not used to limit the indicated devices, elements or components to have a specific direction, or to be constructed and operated in a specific direction; and, in addition to being used to indicate directions or positional relationships, some of the above terms may also be used to indicate other meanings, for example, the term "upper" may also be used to indicate a certain dependency or connection relationship in some cases; for those skilled in the art, the specific meanings of these terms in the embodiments of the present application can be understood according to specific circumstances.

[0025] In addition, the terms "setting", "connection" and "fixed" should be understood in a broad sense. For example, "connection" can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection or an electrical connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be an internal connection between two devices, elements or components; for ordinary technicians in this field, the specific meanings of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0026] Unless otherwise stated, the term "plurality" means two or more.

[0027] In the embodiments of the present application, the character “ / ” indicates that the objects before and after are in an “or” relationship, for example, Z / X means: Z or X; the term “and / or” is a description of the association relationship between objects, indicating that three relationships may exist, for example, Z and / or X means: Z or X, or, three relationships of Z and X.

[0028] It should be noted that, unless there is any conflict, the embodiments and features in the embodiments of the present application can be combined with each other.

[0029] Currently, process data such as fructose, solids, and pH are all issued by the laboratory through manual testing. The testing frequency of each item is once every four hours. The amount of test data for each batch of products is limited and cannot meet Coca-Cola's requirement for exemption from inspection upon entry into the factory. The current fructose detection method is liquid chromatography, and the feedback time for fructose detection data is about 1 hour, which is poor in timeliness. This causes delayed production adjustments and large fluctuations in fructose content indicators, which cannot meet Coca-Cola's requirement that the process capability Cpk is greater than 1.33.

[0030] The applicant has integrated statistical process control (SPC) quality management tools to achieve real-time dynamic monitoring of key product indicators. Once abnormal data is detected, the system will immediately trigger a feedback mechanism to ensure timely adjustment of production parameters, thereby significantly improving the stability of product quality, deepening the refined management level of product indicators, and effectively reducing the frequency of testing, saving testing costs, and effectively compensating for the impact of the lag caused by offline testing on product quality. The control capability of the online monitoring system can be stably maintained above 1.33.

[0031] Specifically, such as Figure 1 As shown, the present application provides an online detection device for high fructose corn syrup, comprising: Multi-parameter detection unit: The first online near-infrared analyzer is deployed at the outlet of the isomerization column to detect the fructose content after isomerization in real time; the second online near-infrared analyzer is installed in the chromatographic feed pipeline to detect the fructose content of the chromatographic feed in real time; the third online near-infrared analyzer is set at the outlet of the evaporation process to monitor the fructose content of the final product of high fructose corn syrup; The first refractometer is installed at the outlet pipe of the isomerization column to detect the solid concentration in real time; the second refractometer is installed at the outlet pipe of the evaporation process to continuously monitor the solid concentration of the final product; The pH sensor is fixed to the inner wall of the mixing tank through a clamp-type fixing bracket to detect the pH value in real time; Data acquisition and transmission unit: It includes an intelligent gateway and an industrial-grade isolation network gate. The intelligent gateway is connected to the multi-parameter detection unit via the Modbus / TCP protocol, and the industrial-grade isolation network gate transmits data to the SPC dynamic control unit; SPC dynamic control unit: The system includes an industrial server, a communication module, and a display terminal. The industrial server is equipped with a data processor and memory for running the SPC analysis algorithm. The communication module connects to the production line PLC system via the OPC UA protocol. The display terminal displays a fructose content trend chart, a solids concentration curve, and a pH fluctuation thermodynamic chart in real time. Abnormal warning module: Integrated into industrial servers and connected to sound and light alarms and PLC controllers, it is used to trigger alarms and parameter adjustment instructions based on preset thresholds.

[0032] Install an online near-infrared analyzer (recommended model Perten IM9500) at the outlet of the isomerization column, the chromatographic feed pipeline, and the outlet of the evaporation process to monitor the fructose content in real time.

[0033] A refractometer (recommended model: RI-201H Showa Denko) is embedded in the outlet pipe of the isomerization column and the outlet pipe of the evaporation process to update the solid concentration data every 10 seconds.

[0034] A pH sensor (model: Mettler TresCon) was fixed to the inner wall of the mixing tank, and the data sampling interval was 5 seconds.

[0035] Data acquisition and transmission unit Smart Gateway: Located in the control box on the production line side, it connects to sensors via the Modbus / TCP protocol and has a built-in embedded processor and flash memory.

[0036] Industrial-grade isolation gateway: Connects the smart gateway and SPC dynamic control unit to ensure secure data transmission across the network.

[0037] SPC dynamic control unit Industrial server: Deployed in the central control room, it contains data processors and storage, and runs SPC analysis algorithms.

[0038] Display terminal: Real-time display of fructose content trend graph, solid concentration curve and pH fluctuation thermodynamic graph.

[0039] Communication module: Connects to the production line PLC system via RS-485 interface and OPC UA protocol.

[0040] Abnormal warning and execution agency Sound and light alarm: installed on the production line operation panel, triggers the alarm after receiving the over-limit signal.

[0041] PLC controller: Links the isomerized column temperature valve and chromatographic feed pump to automatically adjust operating parameters.

[0042] Auxiliary structures 316L stainless steel mounting bracket: used to fix the sensor, the surface is covered with food grade epoxy coating.

[0043] Data storage server: stores historical data and supports SPC report export.

[0044] This application covers three sets of near-infrared analyzers for isomerized columns, chromatographic feed, and evaporation processes, two sets of refractometers, and pH sensors, forming full-process multi-parameter detection, eliminating detection blind spots, and achieving closed-loop control of the entire process of fructose, solids, and pH value.

[0045] Among them, the spectral scanning frequency of the first online near-infrared analyzer, the second online near-infrared analyzer and the third online near-infrared analyzer are all ≥1 time / minute, the detection error range is ≤±0.5%, and they are respectively fixed to the middle section of the pipeline at the outlet of the isomerization column, the chromatographic feed pipeline and the evaporation process outlet through flange interfaces.

[0046] The first refractometer and the second refractometer both have a resolution of ≤0.1%, and are integrated with temperature compensation modules, and are respectively installed on 316L stainless steel brackets of the isomerization column outlet pipe and the evaporation process outlet pipe.

[0047] By limiting the above, this application can greatly improve data accuracy, avoid environmental interference, and ensure detection stability.

[0048] The pH sensor uses a corrosion-resistant glass electrode with a detection accuracy of ±0.05. The clamp-type fixing frame is made of polytetrafluoroethylene and is fixed to the inner wall of the mixing tank by bolts.

[0049] Among them, the abnormal warning module sets the fructose content threshold range to ±1.5%, the solid concentration threshold range to ±0.3%, and the pH value threshold range to ±0.1. When the limit is exceeded, an alarm is issued through an audible and visual alarm, and the operating parameters of the isomerized column temperature valve, chromatographic feed pump and evaporator pressure valve are adjusted through the PLC controller.

[0050] The corrosion-resistant design of the pH sensor and the abnormal warning threshold linked PLC control of the present application can greatly extend the life of the equipment, achieve real-time correction, and reduce quality fluctuations.

[0051] The data traceability system of the SPC dynamic control unit includes a data storage server and a historical database, supports the generation of SPC reports containing X-bar control charts, trend analysis curves and Cpk value calculation results, and exports them through a display terminal.

[0052] The intelligent gateway has a built-in embedded processor and flash memory, which performs filtering, normalization and outlier removal operations on the detection data and then transmits it to the SPC dynamic control unit via industrial Ethernet.

[0053] Through the above-mentioned data storage and edge computing functions, this application can well support quality traceability and localized data processing, reducing cloud dependence.

[0054] The device also includes a 316L stainless steel mounting bracket, and the first online near-infrared analyzer, the second online near-infrared analyzer and the first refractometer are fixed to the outer wall of the pipeline through the mounting bracket, and the surface of the bracket is covered with a food-grade epoxy coating.

[0055] The communication module is connected to the production line PLC system via the RS-485 interface and the OPC UA protocol to adjust the opening of the isomerized column temperature valve, the speed of the chromatographic feed pump, and the pressure value of the evaporator pressure valve in real time.

[0056] The device is compatible with F55 fructose syrup, starch sugar and maltose syrup production lines, and can achieve rapid switching by configuring modular sensor interfaces and parameter preset templates, and supports cloud data synchronization and remote monitoring functions.

[0057] Through the above-mentioned bracket material, communication protocol compatibility and modular expansion limitations, this application can be well adapted to diversified production lines, reduce transformation costs and improve equipment reuse rate.

[0058] Advantages of this application It can monitor the products on the production line intuitively, quickly and in real time, improve the quality stability and uniformity of products, reduce the output of substandard products, reduce production costs, produce at the lowest qualified limit while ensuring product quality, obtain the highest output ratio, and conduct intuitive and effective product quality traceability. It can continuously and in real time detect the indicators of each batch of products on the production line, save labor costs (operators and laboratory technicians), testing costs (testing drugs) and safety costs, increase corporate profits, and the operation and control are simple, intuitive and labor-saving, reducing the labor intensity of production line personnel.

[0059] The above description and drawings sufficiently illustrate the embodiments of the present application to enable those skilled in the art to practice them. Other embodiments may include structural and other changes. The embodiments only represent possible variations. Unless explicitly required, individual components and functions are optional, and the order of operations may vary. Parts and features of some embodiments may be included in or replace parts and features of other embodiments. The embodiments of the present application are not limited to the structures described above and shown in the drawings, and various modifications and changes may be made without departing from the scope thereof. The scope of the present application is limited only by the appended claims.

Claims

1. A fructose syrup online detection device, characterized in that: include, Multi-parameter detection unit: The first online near-infrared analyzer is deployed at the outlet of the isomerization column to detect the fructose content after isomerization in real time; the second online near-infrared analyzer is installed in the chromatographic feed pipeline to detect the fructose content of the chromatographic feed in real time; the third online near-infrared analyzer is set at the outlet of the evaporation process to monitor the fructose content of the final product of high fructose corn syrup; The first refractometer is installed at the outlet pipe of the isomerization column to detect the solid concentration in real time; the second refractometer is installed at the outlet pipe of the evaporation process to continuously monitor the solid concentration of the final product; The pH sensor is fixed to the inner wall of the mixing tank through a clamp-type fixing bracket to detect the pH value in real time; Data acquisition and transmission unit: It includes an intelligent gateway and an industrial-grade isolation network gate. The intelligent gateway is connected to the multi-parameter detection unit via the Modbus / TCP protocol, and the isolation network gate transmits data to the SPC dynamic control unit; SPC dynamic control unit: The system includes an industrial server, a communication module, and a display terminal. The industrial server is equipped with a data processor and memory for running the SPC analysis algorithm. The communication module connects to the production line PLC system via the OPC UA protocol. The display terminal displays a fructose content trend chart, a solids concentration curve, and a pH fluctuation thermodynamic chart in real time. Abnormal warning module: Integrated into industrial servers and connected to sound and light alarms and PLC controllers, it is used to trigger alarms and parameter adjustment instructions based on preset thresholds.

2. The fructose-high corn syrup online detection device according to claim 1, characterized in that: The spectral scanning frequency of the first online near-infrared analyzer, the second online near-infrared analyzer and the third online near-infrared analyzer are all ≥1 time / minute, the detection error range is ≤±0.5%, and they are respectively fixed to the middle section of the pipeline at the outlet of the isomerization column, the chromatographic feed pipeline and the evaporation process outlet through flange interfaces.

3. The on-line detection device for high fructose corn syrup according to claim 1, characterized in that: The first refractometer and the second refractometer both have a resolution of ≤0.1% and are integrated with temperature compensation modules, and are respectively installed on 316L stainless steel brackets of the isomerization column outlet pipe and the evaporation process outlet pipe.

4. The on-line detection device for high fructose corn syrup according to claim 1, characterized in that: The pH sensor uses a corrosion-resistant glass electrode with a detection accuracy of ±0.

05. The clamp-type fixing frame is made of polytetrafluoroethylene and is fixed to the inner wall of the mixing tank by bolts.

5. The on-line detection device for high fructose corn syrup according to claim 1, characterized in that: The abnormal warning module sets the fructose content threshold range to ±1.5%, the solid concentration threshold range to ±0.3%, and the pH value threshold range to ±0.

1. When the limit is exceeded, an alarm is issued through an audible and visual alarm, and the operating parameters of the isomerized column temperature valve, chromatographic feed pump and evaporator pressure valve are adjusted through the PLC controller.

6. The on-line detection device for high fructose corn syrup according to claim 1, characterized in that: The data traceability system of the SPC dynamic control unit includes a data storage server and a historical database, supports the generation of SPC reports containing X-bar control charts, trend analysis curves and Cpk value calculation results, and exports them through a display terminal.

7. The on-line detection device for high fructose corn syrup according to claim 1, characterized in that: The intelligent gateway has a built-in embedded processor and flash memory, which performs filtering, normalization and outlier elimination operations on the detection data and then transmits it to the SPC dynamic control unit via industrial Ethernet.

8. The on-line detection device for high fructose corn syrup according to claim 1, characterized in that: The device also includes a 316L stainless steel mounting bracket, through which the first online near-infrared analyzer, the second online near-infrared analyzer and the first refractometer are fixed to the outer wall of the pipeline, and the surface of the bracket is covered with a food-grade epoxy coating.

9. The on-line detection device for high fructose corn syrup according to claim 1, characterized in that: The communication module is connected to the production line PLC system via the RS-485 interface and the OPC UA protocol to adjust the opening of the isomerized column temperature valve, the speed of the chromatographic feed pump, and the pressure value of the evaporator pressure valve in real time.

10. The on-line detection device for high fructose corn syrup according to claim 1, characterized in that: The device is compatible with F55 fructose syrup, starch sugar and maltose syrup production lines, and can achieve rapid switching by configuring modular sensor interfaces and parameter preset templates. It also supports cloud data synchronization and remote monitoring functions.

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